The "Swiss army knife" among the presetting machines makes sure of cost-efficiency and excels with easy operability

Rohde & Schwarz Teisnach, since 1969 part of Manufacturing Service of Rohde & Schwarz GmbH & Co. KG, manufactures a truly diverse spectrum of parts at its facility
in the Bavarian Forest. Besides manufacturing for the parent company, the factory also serves as service partner for the contract manufacturing of mechanical and electrical components. ZOLLER is present with a total of eight presetting and measuring machines in the areas of tool and mold making, the manufacturing of individual parts and,
in future, also tool grinding. The multi-talent »redomatic« from ZOLLER provides accuracy and cost effectiveness in serial manufacturing – as well as being extremely operator-friendly.

Extensive vertical production
Some 1,400 skilled specialists manufacture individual pieces such as complex tools, through to large series and complex assemblies as well as electro-mechanical systems across all industries in Teisnach on an area over 62,000 m². Electro-mechanical assemblies, systems and bespoke special designs are manufactured for customers ranging from the automotive industry, through aeronautics and aerospace to medical engineering. Production is in small batches with extensive vertical manufacturing - up to 2,700 different parts, manufactured with all types of tools leave the CNC milling department every year at this facility.

The ZOLLER-»redomatic« has been in operation for six years. Every day some 100 to 150 tools are measured in this department, approximately 25 per cent of them shrunken, and loading a total of 25 machines. The parts to be manufactured have to have exactly identical dimensions. Shrunken tools accurate to hundredths of millimeters are required for the double spindles which run precisely in unison in order to achieve an exact result. Shrinking tools to length used to involve enormous manual and thus time expenditure – without being able to achieve the required precision. This problem was solved with the purchase of the ZOLLER »redomatic«: this allowed shrinking of tools easy and fast and with an accuracy of ±10μm – convenient, automatically and absolutely process-reliable.
 

ZOLLER »redomatic«: unique combination of presetting, measuring and shrinking machine

High demands on process reliability and efficiency
The factory makes high demands on process reliability and efficiency. Next to excellent integration into the manufacturing process, demands included easy operability
of the presetting, measuring and shrinking machine. Up to one hundred persons were to operate the machine!
"This was not the only aspect where there were no alternatives to ZOLLER", so Georg Kauschinger, project manager and head of CNC milling. "We have three expert operators/users, but all other 75 persons were able to operate the machine after basic training. If you like, it is self-explanatory." Today, all colleagues can operate the machine in three shifts if required.

Process reliability remains the key for efficient manufacturing. "Here we can rely 100% on the data from the ZOLLER machine", so Georg Kauschinger.

Before the »redomatic« was available it was extremely difficult to even approach accuracy. Franz Wölfl, operator/user since six years: "The tools had to be clamped five to six times to obtain the same length, these required a lot of effort and time – with the »redomatic« I can obtain the required precision virtually at the first attempt!"

The »redomatic« is already the second ZOLLER machine of this series – according to Franz Wölfl the main advantage of this latest generation model versus its predecessor is the continuity of the data from the tool request through to providing the measured tools. As soon as the tool number is entered, all the corresponding tool data is available and the dimensioned drawing is displayed. "This makes our job noticeably easier and avoids mistakes." Mistakes due to manual entering are thus excluded.

Operator-friendly software interface – self-explanatory shrinking system

The ZOLLER »redomatic« thus presents the economical solution for shrinking, presetting and measuring tools to length precisely. This unique combination of presetting, measuring and shrinking machine, the "Swiss army knife of presetting machines", works with Haimer shrinking technology and is equipped with the operator-friendly ZOLLER-»pilot 3.0« image processing technology.

Another advantage of the new »redomatic« highlighted by the users at Rhode & Schwarz is the fully automated sequence of the measuring and shrinking procedure, particularly the automatic diameter presetting of the induction spool. Calibration is also virtually automatic – it just takes one minute every morning.
"There was no alternative to ZOLLER – it was the only machine on the market which met our requirements and offered the required precision combined with ease of operation".

In the end, one of the unbeatable advantages proved to be the ZOLLER service: "As a rule our service is with you within 24 hours, and never later than 48 hours",
confirms Georg Kauschinger.

Another feature in favor of the ZOLLER »redomatic« was the energy-efficient design – the cooler of the »redomatic« is only active when really needed.

Energy-efficient: ZOLLER-»redomatic«

Universal, flexible and unrivalled in terms of operator-friendliness, the "Swiss army knife among the presetting and measuring machines", a "colleague" which everyone enjoys working with efficiently.